AU2003244535B2

AU2003244535B2 - Apparatus having adjustable saws for wood cutting

Info

Publication number: AU2003244535B2
Application number: AU2003244535A
Authority: AU
Inventors: Bradley R. Stager
Original assignee: Key Knife Inc
Current assignee: Key Knife Inc
Priority date: 2002-09-06
Filing date: 2003-09-03
Publication date: 2006-07-20
Anticipated expiration: 2023-09-03
Also published as: CA2438562C; EP1396318A2; EP1396318A3; US20040045634A1; BR0303799A; US7219706B2; CA2438562A1; NZ528052A; AU2003244535A1

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION NAME OF APPLICANT(S):: Key Knife, Inc.

ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 1 Little Collins Street,Melbourne, 3000, Australia INVENTION TITLE: Apparatus having adjustable saws for wood cutting The following statement is a full description of this invention, including the best method of performing it known to me/us:- Field of the Invention The present invention relates to an apparatus having adjustable saws for wood cutting, particularly for use in log and lumber processing in a lumber mill.

Background of the Invention In order to produce squared lumber from a log, curved or wany edges of the log must be removed. To optimize the number of boards that can be obtained from the log, boards of optimum size are identified that will substantially fill the cross-sectional area of the log, leaving a number of such wany edges. In a process known as "profiling," a cutting head (also known as a "profiling head") is used to cut or chip away the wany edges, and this may be done before the boards are sawed from the log. Particularly, the cutting head cuts a corner that extends along the length of the log and that defines an outer side of one board and at least part of the upper or lower face of an adjacent board. To cut the corner, the cutting head rotates about an axis and has cutting surfaces oriented at right angles with respect to each other.

The cutting head has in the past typically included a knife for cutting the aforementioned upper or lower face in the example given above, the face defining a plane that is parallel to the axis of rotation of the cutting head ("facing cut"), and a saw for cutting the aforementioned outer side ("slicing cut"), which defines a plane that is perpendicular to the axis of rotation. More recently, cutting heads have been provided which employ knives for making both the slicing cut and the facing cut.

The speed of the profiling operation is increased if the wany edges for a number of boards can be removed by the same cutting head. A cutting head that can be used to cut away two wany edges at one time has at least one additional set of knives. The knives of the additional set are disposed a different radial distance from the axis of rotation than the first knives and are displaced axially therefrom as well.

For example, the first knives may be used to cut a first comer defined by an outer side of a first board and at least part of the upper face of a second board that lies beneath and extends laterally beyond the first board. The additional knives may simultaneously be used to cut an adjacent corner defined by an outer side of the second board and at least part of the upper face of a third board that lies beneath and extends laterally beyond the second board. The difference in radial positioning of the first knives relative to the additional knives, as well as the difference in axial positioning of the first knives relative to the additional knives, may define either the thickness of one of the boards or the difference in width between two adjacent boards. The absolute positioning of all of the knives of the cutting heads used to profile the log, in concert with the positioning of the cutting heads themselves, defines the dimensions of board lumber sawn from the log.

Examples of adjustable cutting heads are found in Dietz, Disclosure Document DE 44 19 324 ("Dietz") and Linck, European Patent Application No. 96107714.6 ("Linck"). Dietz discloses an outer comer milling machine and an inner comer milling machine, each resembling a pot, one lying at least partially within the other. Each of the corner milling machines is adapted to cut a corner and is equipped for this purpose with a cleaver on the circumference surface and a plane blade oriented at right angles to the cleaver. "Adjustment units" are used to adjust the axial spacing between the two corner milling machines. The "adjustment units" are not de'scribed, but appear to be electric motors. Radial adjustment is not provided, and axial C adjustment appears to require feed-back control of the motors to find and maintain a command spacing. This spacing can change as a result of the forces encountered by the milling machines

I

and at least some time will be required for the controller and feedback mechanism to restore proper spacing, resulting in imprecise cutting.

tn Linck discloses a milling head having a large diameter ring of cleavers and a smaller I diameter ring of cleavers. The cleavers have their cutting edges aligned with the axis of M€ revolution of the milling head. The cleavers are attached to cleaver carriers which are fastened C with screws to respective cleaver supports. The radial disposition of the cleaver supports can be adjusted by loosening the screws. The cleaver supports can also be moved in axial rails within the calTriers and can be locked in at different axial positions with terminal blocks and screws Disksaw segments are installed between the cleavers in the smaller ring. These are stated as being adjustable but no means for adjusting the disksaw segments is disclosed. Moreover, while the position of the cleavers can be adjusted both axially and radially, holding the cleavers in position depends on frictional forces exerted by tightening screws, so that there is no provision for positively locking the position of the cleavers.

Another problem with such cutting heads generally is that they are prone to load up with sawdust.

3 P ,OPERLKA1 2327330 spC d.2A0 ,0 -4- It is an object of this invention to provide an apparatus for cutting an article wood that will overcome one or more of the foregoing problems and maximize the effectiveness of the wood cutting process.

Summary of the Invention According to one aspect of the present invention provides an apparatus for cutting an article of wood, comprising: a cutting head adapted for rotation about an axis, said cutting head including at least two flat circular disk-saws axially adjustably spaced relative to each other, each disksaw having respective pluralities of cutting teeth, said disk-saws attached to said cutting head and defining respective distinct outer cutting diameters for producing respective slicing cuts,wherein a first one of said disk-saws defines an annular ring having an inner diameter, the outer cutting diameter of said first disk-saw being greater than the outer cutting diameter of a second one of said disk-saws, the outer cutting diameter of said second disk-saw being less than the inner diameter of said first disk-saw for nesting said second disk-saw inside said first disk-saw.

Preferably, there is provided at least one control plate interdisposed between at least one of said disk-saws and said cutting head, for axially positioning said at least one disk-saw with respect to said cutting head.

Preferably, there is provided at least two control plates, at least one control plate being interdisposed between a first said disk-saw and said cutting head, and at least one control plate being interdisposed between the first said disk-saw and a second said disksaw.

Preferably, wherein the inner diameter of said first disk-saw, said second disk-saw and said cutting head define a space therebetween, and wherein the cutting head is relieved behind at least said cutting teeth of said second disk-saw to permit sawdust that migrates past said second disk-saw into the space and out through said cutting head.

P:\OPER\SgMI 2327330 2spadm.26I0IM 4a z respective slicing cuts in the wood, wherein a first one of said disk-saws defines an annular N, ring having an inner diameter, the outer cutting diameter of said first disk-saw being greater than the outer cutting diameter of a second one of said disk-saws, the outer cutting diameter of said second disk-saw being less than the inner diameter of said first disk-saw for nesting said second disk-saw inside said first disk-saw According to another aspect, the present invention provides an apparatus for cutting an article of wood, comprising: a cutting head adapted for rotation about an axis, said cutting head including at least two flat circular disk-saws axially adjustably spaced relative to each other, each disksaw having respective pluralities of cutting teeth, said disk-saws attached to said cutting head and defining respective distinct outer cutting diameters for producing respective slicing cuts in the wood, wherein said cutting teeth include respective first sides perpendicular to said axis for producing respective slicing cuts in the wood, and respective second sides parallel to said axis for producing respective facing cuts in the wood.

Thcre .re, it is a principal object of the present invention to provide a novel and improved apparatus having adjustable saws for wood cutting.

It is another object of the present invention to provide such an apparatus that provides for the advantages inherent in the use of saw blades for cutting multiple corners in the wood.

It is a still another object of the present invention to provide such an apparatus providing for ease of adjustment of the cutting position of the saws.

It is yet another object of the present invention to provide such an apparatus providing for positive locking of the saws in respective cutting positions.

It is a further object of the present invention to provide such an apparatus that minimizes required maintenance and maximizes the effectiveness of the wood cutting process.

It is yet a further object of the present invention to provide such an apparatus that minimizes the accumulation of sawdust on the saws.

The foregoing and other objects, features and advantages of the present invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the following drawings.

Brief Description of the Drawings Figure 1 is a plan view of an apparatus for cutting an article of wood according to the present invention.

Figure 2 is side elevation of the apparatus of Figure 1.

Figure 3A is a cross-section of a log.

Figure 3B is a cross-section of the log of Figure 3A as operated on by the apparatus of Figure 1.

Figure 3C is the cross-section of Figure 3B shown with boards of lumber identified.

Figure 4 is a pictorial view of a cutting head according to the present invention, showing a front side of the cutting head.

Figure 5 is an exploded view of the cutting head of Figure 4.

Figure 6 is a side view of the cutting head of Figure 4, showing a rear side of the cutting head.

Figure 7A is a pictorial view of a representative knife for use with the present invention,.

showing a top side of the knife.

Figure 7B is a pictorial view of the knife of Figure 7A, showing a bottom side of the knife.

Figure 8 is an exploded view of a portion of a cutting head having two sets of knives according to the present invention.

Figure 9 is a plan view of a second embodiment of an apparatus for cutting an article of wood according to the present invention.

Figure 10A is a plan view of the cutting head of Figure 4, showing nested disk-saws in a first relative axial position.

Figure 10B is a plan view of the cutting head of Figure 8A, showing the nested disk-saws in a second axial position.

Figure 11 is an exploded view of the cutting head of Figure 4, showing a rear side of the cutting head.

Detailed Description of a Preferred Embodiment Referring to Figure 1, an apparatus, 8 for cutting an article of wood 14 is shown with four cutting heads 10. The article of wood 14 is, in this example, a log shown in cross-section Comers are being cut from the log by the cutting heads 10 as the log passes the cutting heads in the direction indicated as "flow" in Figure 2 in a milling process known as "profiling." This process configures the log from the roughly circular cross-section shown in Figure 3A to that shown in Figure 3B. While such profiling of logs is an exemplary use of the present invention, the apparatus 8 may be used for cutting any article.

By cutting wany edges from the log with the cutting heads, the cross-section of the log as shown in Figure 3B has been optimized for cutting pieces 18 of board lumber, as depicted in Figure 3C. The cutting heads 10 rotate about respective axes of rotation as shown in Figure 1. The cutting heads may be moved in the direction of the arrows shown in Figures 1 and 2 to accommodate logs of different diameters.

Turning to Figure 4, a preferred cutting head 10 having adjustable saws according to the present invention has two disk-saws 11, 13 with associated cutting teeth 11 a, I 3a. The disk-saws are spaced apart along the axis The cutting teeth 1 Ia, 13a define distinct outer cutting diameters

D,

1 and D 3 of the disk-saws. The outer cutting diameter of the disk-saw 13 is chosen as being the greater outer cutting diameter for purposes of the discussion herein. While shown as integral parts for simplicity, the flat, circular disk-saws 11 and 13 may comprise any number of separate disk-saw segments, which may facilitate repair and replacement of the disk-saws, as well as maintenance of the apparatus generally. Also, while two disk-saws are shown and described as preferred, any number of disk-saws may be provided. Referring back to Figure 1, the disk-saws 11 and 13 of a particular cutting head 10, as they are rotated about the axis produce respective slicing cuts C,, 1

C,,

3 and facing cuts Cf 1 Cf, 3 on the log 14.

An outstanding feature of the cutting head 10 according to one aspect of the invention is that it provides for adjusting the relative axial positioning of the disk-saws 11, 13, by the inclusion or deletion of one or more control plates 20, such as shown in Figure 5. Both the absolute and relative axial positions of the disk-saws may be adjusted by appropriate selection and placement of the control plates 20. In the example shown, a single control plate 20 is interdisposed between the disk-saw 11 and a body portion 1 Da of the cutting head 10. Additional control plates 20 may be stacked together with the control plate 20, and any number of similar control plates may be interdisposed between the disk-saw 13 and the body portion In a preferred embodiment of the invention, the control plates include apertures matching corresponding apertures 15a and 15b, through the disk-saw and the body portion respectively, permitting bolts 15 used to mount the disk-saws to the cutting head 10 to pass therethrough. Other adaptations of the control plates 20 and the cutting head 10 may be employed to achieve the same function without departing from the principles of the invention.

As shown in Figure 5, the control plates are flat pieces of metal of predetermined thickness, preferably, though not necessarily formed in an annular configuration. While a single annular control plate is shown for axially positioning the disk-saw, smaller, individual control plates may be employed at selected bolt locations to produce the same result.

The difference in the relative axial positioning between the disk-saws 11 and 13 is shown in Figure 1 as the distance Referring to Figure 3C, this distance may be used to define either the difference in width between two adjacent boards 18a and 18b, or the thickness of a single board 18c. The absolute positioning of the disk-saws 11 and 13 of opposed pairs of cutting heads 10 provides the absolute dimensions of the boards 18. The control plates provide for such positioning in discrete, precisely defined steps, and positioning is positively and accurately maintained without readjustment regardless of the amount of use and wear of the cutting head.

The control plates are highly economical to produce, and provide for substantially reducing the mechanical complexity of the cutting head, resulting in further savings in initial cost, maintenance and repair. By use of the control plates 20, the dimensions of different boards 18 may be optimized to minimize the amount of the wany material that must be removed from the log and thereby to maximize the size of the boards.

Turning to Figure 6, according to another aspect of the invention, the cutting head preferably includes in addition to the disk-saws at least one set of knives K. A representative knife K having dual cutting edges 23a, 23b is shown in Figures 7A and 7B. The knives K as they rotate about the axis produce respective semi-cylindrical facing cuts CK (Figure 1) on the log 14. The outer cutting edges (23a as shown in Figure 6) of the knives K define an outer cutting diameter for the knives with respect to the axis of rotation Additional sets of knives may be employed, and the axial and radial positioning of the knives may be adjustably controlled with control plates similar to the control plates 20, such as described in the assignee's patent application Serial No. 10/081,444.

For example, turning to Figures 8 and 9, a first set of four knives K, may be provided on a body portion 12a that is bolted to the cutting head 10 for producing a facing cut Ckaon the log at a first outer cutting diameter. A second set of knives Kb may also be provided on a body portion 12b that is bolted either to the cutting head 10 (not shown in Figure 8) or the body portion 12a for producing a facing cut Ckb on the log at a second outer cutting diameter that is distinct from the outer cutting diameter of the first set of knives Base outer cutting diameters are defined by the radial size of the respective body portions 12.

In addition, the radial positioning of the knives may be further adjusted from their base radial positioning as defined by the body portions 12 themselves, by the use of one or more control plates 21 (Figure 9) interdisposed between clamping mechanisms 30 for the knives and the body portions 12 and held in place such as by the use of bolts 15. Like the control plates the control plates 21 are flat pieces of metal of predetermined thickness that provide for such positioning in discrete, precisely defined steps, and positioning is positively and accurately maintained without readjustment regardless of the amount of use and wear of the cutting head.

Figure 8 also illustrates the use of a control plate 22 providing for relative axial positioning of the two sets of knives K. and Kb One or more of the control plates 22 may be interdisposed between the body portions 12a and 12b and held in place such as by the use of bolts As will be readily appreciated, suitably disposed control plates 22 may also be used to adjust the absolute axial positions of the two sets of knives. Like the control plates 20, the control plates 22 are flat pieces of metal of predetermined thickness that provide for such positioning in discrete, precisely defined steps, and positioning is positively and accurately maintained without readjustment regardless of the amount of use and wear of the cutting head.

Figure 9 also illustrates the use of three disk-saws, 11, 13 and 9, to show how the concept may be generalized. The disk-saws produce respective slicing cuts 1 and C, 9 and respective facing cuts C.

1

C.

3 and Cf, on the log 14. The facing cut in particular, is aligned with the facing cut Ck, of the adjacent set of knives the outer cutting diameter of the disk-saw 9 is the same as the outer cutting diameter of the set of knives Additional disksaws may also be employed as desired, along with any number of sets of knives or any other desired elements.

Turning to yet another aspect of the invention, as mentioned, the disk-saws define respective outer cutting diameters D. In Figures 4 6, the disk-saw referred to as 13 is shown as having a greater outer cutting diameter D 13 than the outer cutting diameter D 1 of the disk-saw 11.

In that case, the disk-saw 13 is preferably provided as an annular ring having a corresponding inner diameter d 13 (see Figure As seen most clearly in Figure 4, the outer cutting diameter D, of the disk-saw 11 is preferably less than the inner diameter d 13 of the disk-saw 13, so that the disk-saw 11 may be nested axially within the disk-saw 13 and may therefore be adjusted to extend axially beyond the disk-saw 13 any desired amount. For example, comparing Figures and 10B, the disk-saw 11 is shown in a first relative position (Figure 10A) in which the disk-saw 11, nested in the disk-saw 13, extends axially beyond a front face of the disk-saw 13 an amount and a second relative position (Figure 10B) in which the disk-saw 11 extends beyond the front face of the disk-saw 13 a lesser amount "d2" while remaining nested within the disk-saw 13.

In addition, also as best seen in Figure 4, it is preferable that the diameter D 1 I of the disksaw 11 is just slightly less than the inner diameter d 13 of the disk-saw 13, so that the space available therebetween for conducting sawdust into the cutting head 10 is minimized. Preferably, the radial clearance between the nested disk-saws is no greater than about 0.020", to minimize packing of sawdust between the disk-saws.

Figure 11 illustrates still another aspect of the invention in which, preferably, the cutting head 10 is relieved such that there is an aperture 31 therethrough (also shown in Figure and there is a route as shown at 32 behind at least the cutting teeth of the smaller diameter disk-saw 11 to the aperture 31, for conducting sawdust entering the space between the disk-saws into the cutting head to the exterior of the cutting head. For example, even where the two cutting heads are nested together and the clearance between the outer cutting diameter D 1 I (Figure 4) of the cutting head 11 and the inner diameter d 13 (Figure 5) of the cutting head 13 is essentially zero, sawdust may still enter the cutting head through the spaces between the cutting teeth 1 la. The reliefs 31 and 32 cooperate with the maximum radial clearance indicated above to minimize or prevent packing of sawdust around the disk-saws.

Referring back to Figure 2, it may be noted that the log 14 may be curved, having a curved elongate axis 24. In that circumstance, the heads 10 may all be moved together, upwardly or downwardly in the direction of the arrows, to follow the curvature of the log as it is fed along the direction of flow. This permits profiling a curved log according to the invention in such manner as to follow the grain, which optimizes the strength of the resulting lumber. The curved boards resulting from profiling the curved log may be straightened in subsequent processing with known techniques.

It is to be recognized that, while a particular adjustable profiling head for a wood cutting apparatus has been shown and described as preferred, other configurations and methods could be utilized, in addition to those already mentioned, without departing from the principles of the invention.

The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions to exclude equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Claims

1. An apparatus for cutting an article of wood, comprising: a cutting head adapted for rotation about an axis, said cutting head including at least two flat circular disk-saws axially adjustably spaced relative to each other, each disk- saw having respective pluralities of cutting teeth, said disk-saws attached to said cutting head and defining respective distinct outer cutting diameters for producing respective slicing cuts in the wood, wherein a first one of said disk-saws defines an annular ring having an inner diameter, the outer cutting diameter of said first disk-saw being greater than the outer cutting diameter of a second one of said disk-saws, the outer cutting diameter of said second disk-saw being less than the inner diameter of said first disk-saw for nesting said second disk-saw inside said first disk-saw.

2. An apparatus as claimed in claim 1, further comprising at least one control plate interdisposed between at least one of said disk-saws and said cutting head, for axially positioning said at least one disk-saw with respect to said cutting head.

3. An apparatus as claimed in claim 2, further comprising at least two control plates, at least one control plate being interdisposed between a first said disk-saw and said cutting head, and at least one control plate being interdisposed between the first said disk-saw and a second said disk-saw.

4. An apparatus as claimed claim 2, wherein the inner diameter of said first disk-saw, said second disk-saw and said cutting head define a space therebetween, and wherein the cutting head is relieved behind at least said cutting teeth of said second disk-saw to permit sawdust that migrates past said second disk-saw into the space and out through said cutting head. An apparatus as claimed in claim further comprising at least two control plates, at least one control plate being interdisposed between a first said disk-saw and said cutting head, and at least one control plate being interdisposed between the first said disk-saw and a second said disk-saw.

6. An apparatus as claimed in claim 4 or claim 5, wherein said cutting teeth include PAOPERILKA\I2327330 rp doc-28""f NO respective first sides perpendicular to said axis for producing respective slicing cuts in the wood, and respective second sides parallel to said axis for producing respective facing cuts in the wood.

7. An apparatus as claimed in claim 2, wherein said cutting teeth include respective first sides perpendicular to said axis for producing respective slicing cuts in the wood, and ,,respective second sides parallel to said axis for producing respective facing cuts in the wood.

8. An apparatus as claimed in claim 7, further comprising at least two control plates, at least one control plate being interdisposed between a first said disk-saw and said cutting head, and at least one control plate being interdisposed between the first said disk-saw and a second said disk-saw.

9. An apparatus as claimed in claim 1, wherein the inner diameter of said first disk- saw, said second disk-saw and said cutting head define a space therebetween, and wherein the cutting head is relieved behind at least said cutting teeth of said second disk-saw to permit sawdust that migrates past said second disk-saw into the space and out through said cutting head. An apparatus as claimed in claim 9, wherein said cutting teeth include respective first sides perpendicular to said axis for producing respective slicing cuts in the wood, and respective second sides parallel to said axis for producing respective facing cuts in the wood.

11. An apparatus as claimed in claim 1, wherein said cutting teeth include respective first sides perpendicular to said axis for producing respective slicing cuts in the wood, and respective second sides parallel to said axis for producing respective facing cuts in the wood. I P:\OPER\LKAM 2327330 spc doc-28061O6

16- 12. An apparatus substantially as hereinbefore described with reference to the drawings and/or Examples. Dated this 28th day of June, 2006 Key Knife, Inc. by DAVIES COLLISON CAVE Patent Attorneys for the applicant